Integrated Formulation–Process Strategies for Optimised Extrusion and Printability Outcomes in Additive Manufacture of Oral Solid Dosage Forms Aston University in United Kingdom

This PhD project at Aston University, based in the College of Health and Life Sciences, focuses on advancing extrusion-based three-dimensional (3D) printing for personalised oral solid dosage forms. The research addresses key challenges in the field, including limited throughput, variable dose uniformity, and inconsistent print reliability, by developing integrated formulation and process strategies. The project aims to optimise extrusion performance through coordinated advances in feedstock formulation and extrusion control, leveraging materials science, pharmaceutical engineering, and process analytics.

The first research objective is to engineer hot-melt extrusion (HME) filaments and semi-solid extrusion (SSE) pastes with rheological properties tailored for continuous, stable deposition. Formulation work will emphasise polymer-based systems, active pharmaceutical ingredient (API) particle-size control, and the use of flow modifiers to achieve predictable shear-thinning behaviour, rapid structural recovery, and homogeneous API distribution. Physicochemical characterisation using techniques such as HPLC, DSC, TGA, XRPD, and FTIR will provide a robust evidence base for future developments and ensure formulations can be extruded cleanly and maintain their shape post-deposition.

The second objective targets hardware-driven improvements in extrusion consistency. The project will evaluate optimised nozzle geometries, enhanced thermal management, and the integration of pressure, torque, and temperature dynamics to minimise clogging, thermal gradients, and flow variability. A structured design-of-experiments (DOE) framework will link formulation attributes and hardware parameters to critical quality attributes, including dose uniformity, tablet geometry, mechanical strength, and dissolution performance. The anticipated outcomes include a validated operating space for higher throughput and improved quality of feed material and print outcomes, as well as practical guidelines for feedstock preparation and process control that may inform future policy.

This research will provide the scientific and engineering foundations necessary to advance extrusion-based 3D printing toward reliable, GMP-compatible manufacturing of personalised oral medicines. The project is based at the Aston Campus in Birmingham, UK, and requires regular in-person attendance. Candidates should have a First or Upper Second Class undergraduate degree in a relevant subject, or a First or Upper Second Class undergraduate degree and a Merit or Distinction in a relevant Masters degree. Overseas qualifications will be considered if equivalent. Applicants must provide English language transcripts and certificates, a research statement, personal statement, CV, two academic references, evidence of English language proficiency, and a copy of their passport. Overseas applicants must pay the difference between Home and Overseas tuition fees (£17,712 for 2026/7) and confirm their ability to provide this funding. Associated consumables costs should be discussed with the supervisor prior to application.

Applications are accepted year-round. Interviews will be conducted online via Microsoft Teams. For further information or to discuss consumables costs, contact Dr Daniel Kirby at [email protected]. Apply online via the provided link, selecting 'Research - Health Sciences' from the application form options. Ensure all supporting documents are uploaded. References include recent publications by Curti, Kirby, and Russell on formulation approaches and printability outcomes in 3D printing of oral dosage forms.